Mottled pile fabric and method of making same



J. E. TROY May 28, 1963 MOTTLED PILE FABRIC AND METHOD OF MAKING SAME 2 Sheets-Sheet 1 Filed June 29, 1959 III I III I III III

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INVENT OR BY 'W ATTORNEYS May 28, 1963 J. E. TROY 3,091,263

MOTTLED FILE! FABRIC AND METHOD OF MAKING SAME Filed June 29, 1959 2 Sheets-Sheet 2 INVENTOR J AM as ET oY- 5y bill,

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ATTORNEYS United rates Patent 3,9l,253 Patented May 28, 1963 1 3,13%,263 MOTTLED PHJE FABRIC AND METHUD OF MAKING SAD E James E. Troy, Spray, Nil, assignor to Fieldcrest Miils, Inc, Spray, NAL, a corporation of Deiaware Filed June 29, 1959, Ser. No. 823,391 14 Claims. (Cl. 1394tl2) This invention relates to pile fabrics, such as are used for carpets, rugs and the like, and more especially, to a novel pile fabric having a mottled or tweedy appearance.

Various carpet fabrics have been produced heretofore winch were provided with tufts of different textures and/ or colors. The pile of such prior art fabrics was formed by intertwisted or plied pile yarn strands of different colors or kinds which projected upwardly from between the same adjacent ground warps throughout the length of the fabric. All strands which passed between and formed rows of loops or tufts between any two ground warps tended to adhere to each other rather than intermingling with pile strands in adjacent rows of loops and/ or tufts. In most instances, therefore, definite streaks of one or more textures and/ or colors were visible in the pile face of the finished fabric.

It is therefore a primary object of this invention to pro- Vide a novel fabric and method of making the same wherein two or more independent pile yarns of relatively different color or kind project from each selected block defined between adjacent ground warp and weft portions and wherein the fabric is so woven that the pile yarns in each block inherently tend to spread apart and thereby intermingle with the pile yarn portions in adjacent blocks so the finished fabric is devoid of any definite or noticeable streaks of any single texture or color.

It is another object of this invention to provide a novel cut pile fabric and method of making the same in which the face of the fabric has variegated tufts and all tufts of any one color are distributed among tufts of other colors to the eX'tent that the face of the fabric is entirely devoid of streaks of any single color and is devoid of indication of any particular type of patterning.

It is a more specific object of this invention to provide a pile fabric and method of making the same in which groups of warp yarns are interwoven with Weft yarns to form a base with different colors or types of pile yarns being shogged over and above respective groups of warp yarns and under weft yarns with the pile yarns being divided into groups, including one or more yarns at alter nate groups of ground warps and two or more pile yarns at intervening groups of ground warps, the pile yarns being severed where they pass over the respective groups of warp yarns to form at least three pile tuft strands of different characteristics, such as color, texture and the like, in each opening or block defined between adjacent groups of warp yarns and adjacent weft yarns.

It is another object of this invention to provide a novel variegated pile fabric and method of making the same, in which warps are interwoven with wefts and a single or odd number of pile yarns of different colors are raised and shogged over each of certain alternately spaced warps or groups of warps, and wherein an even number of pile yarns, which are also of relatively different colors and which differ in color from the colors of the aforementioned pile yarns, are raised and shogged over each of certain intervening groups of ground warps, the odd and even pile yarns being looped under alternate wefts at one side of the respective warps and under intervening wefts at the other side of the respective warps. The pile loops thus formed over the warps may be severed at their upper portions to form variegated tufts of random disposition thereby producing a mottled fabric which, in appearance, does not suggest any particular patterning.

The novel fabric is further enhanced by the use of hand twisted or frieze type yarns.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which FIGURE 1 is an exploded diagrammatic plan view illustrating one form of the novel fabric as it is woven and showing ends of warpwise pile wires beneath some of the loops and above respective warps;

FIGURE 2 is another diagrammatic plan view similar to FIGURE -1 showing blocks of tufts of different colors or kinds formed by severing the loops of the fabric shown in FIGURE 1 at points above respective groups of ground warps;

FIGURE 3 is a schematic elevational view showing how pile wires maybe used for forming loops and cutting the same to produce fabrics according to the present invention;

FIGURE 4 is a top plan view of a portion of the improved fabric, wherein all the loops have been severed and showing, in particular, how tufts of different colors or kinds are irregularly positioned throughout the face of the fabric so the fabric has a mottled appearance;

FIGURE 5 is a greatly enlarged fragmentary plan view of the first form of the mottled pile fabric;

FIGURE 6 is a warpwise vertical sectional view through a portion of the fabric in which all the loops have been severed;

FIGURE 7 is a view looking at the right-hand side of FIGURE 6; i.e., a weftwise vertical sectional view through a portion of the fabric;

FIGURE 8 is a view similar to FIGURE 1 showing a second form of the fabric wherein two pile yarns of different types or colors are looped over alternately spaced groups of ground warps and three pile yarns of other d'nferent types or colors are looped over intervening groups of ground warps;

FIGURE 9 is a view similar to FIGURE 6 showing, diagrammatically, how tufts may be arranged after the loops in the portion of fabric shown in FIGURE 8 have been severed;

FIGURE 10 is a view similar to FIGURE 6 showing uncut ground-engaging loops, medium height loops and cut-loop tuft portions projecting from the face of the fabric.

Previous attempts at making mottled pile fabric including several different colors of pile yarn or several different types of pile yarn have involved weaving a base from ground warp and weft yarns while looping pile yarns over weftwise pile wires and wherein the warps have passed beneath successive wefts between adjacent pile wires and have been retained between adjacent warps throughout the length of the fabric. When loops of this character were subsequently severed, most of the tufts of any one color or kind would largely appear in the form of lineal rows of tufts, substantially devoid of any random appearance.

In some instances, fabrics woven in the manner last described have had pile yarns which included two or more twisted strands of different colors or kinds so as to produce a more irregular, random appearance to the face of the fabric. However, this would still result in noticeable streaks of alternating colors of pile strands or tufts of alternating colors or characteristics, notwithstanding the fact that it was necessary to carefully ply the two or more yarns together and the necessity of inserting and removing weftwise pile wires still remained.

I have found that by providing an odd number of different colored tufts in each of certain boxes or spaces defined between adjacent warp and weft yarns, and by originally inserting these tufts by passing pile yarns across and above warp yarns and beneath weft yarns in alternation and then cutting the same, variegated tufts, or tufts made from jute.

FIGURES l and 3.

,of different characteristics, are formed which are so in a one-shot weave with an odd number (one or more) of pile yarns of a given color or type being raised and shogged across and above alternate groups of warps and an even number (two or more) of pile yarns being raised and shogged across and above intervening groups of warps etween-the alternate groups with all the latter yarns being of different colors or kinds.

Referring to FIGURE 1, the first form of fabric generally comprises groups of warp yarns including alternate groups and intervening groups 11. There are four warps in each group 10, 11, in this instance, although a greater or lesser number of ground warps may be used. Also, these warps are shown in the form of chain warps interwoven with weft yarns 12, which are shown in the form ,of double wefts or two-strand wefts, preferably The wefts 12 may be of the single strand type and are merely shown in the form of double strand .wefts, since the fabric may be woven on looms of the type known as Clark looms and disclosed in United States Patent Nos. 2,437,378; 2,437,379 and 2,860,669, for example.

Looms of the character disclosed in the latter patents include .means for weaving a base or ground fabric from warp and weft yarns and are provided with pile yarn guides IG (FIGURE 3), through which respective continuous pile yarns pass. The guides G dip or move downwardly from a position above the fabric, whereupon double weft yarns are inserted through the open shed, formed of the ground warps, and over the strands of pile yarns, the double weft being inserted by means of an elongated needle N.

Upon groundwarps being inserted, the pile yarn guides G move upwardly from a position within the shed and are then shifted laterally substantially simultaneously with the "beat-up stroke of the reed and then again moved downwardly preparatory to another double weft yarn beinginserted over strands of pile yarn, In so doing, the

pileyarns are looped over corresponding groups of warp yarns and respective warpwise loop forming fingers or pile wires -P. Portions of such pile wires are shown in The pile wires P may be provided withloop forming stages of different heights and may be shifted longitudinally of the warp to present stages of different heights to loop forming position to form corresponding loops ofdifierent heights (see United States Patent 'No. 2,860,664).

As heretofore stated, 'Ihave discovered that-pile yarns of different colors may be interwoven with the base above alternate groups of ground warps to form variegated loops which, when out, form pile tufts of difierent colors randomly positioned throughout the face of the fabric. To this end, in the first form of the invention 15,are each loopedbeneath a weft 12 and then raised and shogged over a respective pile wire P. Pile yarns 15 are then looped beneath the next succeeding weft yarn. Of course, the single pile yarns are then raised and shogged in a reverse direction back across the same respective group of warps and, thence, beneath the next succeeding weft. Thus, the pile yarns 15 are looped beneath alternate wefts 12 at one side of each respective group of warps 10- and they are looped beneath intervening wefts at the other side of each respective group of warps 10. The two pile warps 16, 17, are also shogged over intervening groups of ground warps 11, passed beneath alternate wefts 12 at one side of the respective groups of ground warps 11 and passed beneath intervening wefts at the other side of each alternate group 11, this procedure being repeated throu-ghoutthe weaving of the fabric.

In order to produce .a cut pile fabric, the loops may be cut by asuitable shearing apparatus or by any other suit able means, such asthat shown in FIGURE 3. It will be observed that each pile wire P is provided with a cutter blade 20 adjacent its free end portion and forwardly of the surface of the pile wire over which the loops ,are

formed. Thus, as the fabric is taken up by the usual take-up mechanism, not shown, the loops move against the inclined upper edge of blade 20 and are thus severed.

It will be observed in FIGURE 2 that, when the loops which overlie ground warps 1t 11 are severed, this provides three distinct tufts of difiierent color or different characteristics, as the case may be, in each box defined between adjacent wefts 12 and adjacent groups of' chain warps 10, 11.

It might be statedthat, since the pile yarn guides, such as that indicated at G in FIGURE 3, move downwardly through the shed at one side of each respective group of ground war-ps and move upwardly and laterally in opposite directions, this causes the yarns to be pushed down- -wardly against portions of adjacent pile yarns wihch had previouslybeen inserted by respective pile yarn guides G. This results in the loops being crowded together at their bases and also causes them to upset or displace each other because of the last inserted portion of each respective pile yarn being forced downwardly by the next guides also move across and above the intervening groups of ground warps 10 and thus insert, portions X of the respectiverpile yarns 15 into the same boxes in which the respective portions Y of yarns 16, 17 had just previously beenpositioned. Thus, the portions X move downwardly and press against the respective portions Y of yarns 16, 17. In so doing, portions X relatively displace portions Y to some extent.

Thus, after the yarns have been severed, they do not in fact assume the positions shown in FIGURE 2, the tufts merely being shown in block form in FIGURE'Z I to clarify the positions thatthey would occupy were they not twisted and relatively displaced to some extent by the successive insertion of respective portions of pileyarn 'in the blocks defined between adjacent warp and weft .yarns which causes them to become further intermingled and to spring into relatively irregular positions when they are severed as shown in FIGURE 2. This results in the actual fabric appearing as shown in FIGURES 4, 5, 6 and 7,.Wherein it will be noted that it is practically impossible to detect any particular lineal arrangement of tufts of any particular color. It should be noted that FIGURE 5 is an inked reproduction of anactual magnified photograph of a portion of the first form'of the fabric, with shading to indicate the different colors of the tufts.

In FIGURES 8 and 9, a second form of the invention is shown wherein the fabric is quite similar to the first form of fabric with the exception that alternate groups of warps ltta have groups 15a of three pile yarns of different colors or kinds associated therewith while intervening groups of warps 11a have respective groups 16a of two pile yarns of different colors or kinds associated therewith. The groups of odd numbers of pile yarns 15a include individual yarns or pile strands a, b, c and the groups of even numbers of pile yarns 16:: include individual pile yarns or strands d and e. The groups of pile yarns 15a, 16a are interwoven with wefts 12a and respective groups of ground warps 19a, 11a in substantially the same manner as the respective single pile yarns 15 and pairs of pile yarns 16, 17 are interwoven with the wefts 12 and the respective groups of ground warps 1t 11. Accordingly, a further description of the pile fabric in this respect is deemed unnecessary.

It will be observed in FIGURE 9 that severing of the loops formed over the groups a, 11a of pile yarns produce five tufts of different colors or kinds in each block defined between adjacent groups of warps and wefts, these tufts being identified by the same reference numerals as are applied to the respective pile yarns in FIG- URE 8, for purposes of clarity. Here again, the position in which the tufts are shown in FIGURE 9 is diagrammatic to the extent that the tufts are shown in alinement with each other. However, as heretofore stated, adjacent porions of pile yarn are actually shifted to various positions as the fabric is woven so the tufts are randomly positioned insofar as color and/ or texture thereof is concerned. Thus, with the exception of greater tuft density, the finished fabric actually appears substantially the same as the fabric of the first form of the invention shown in FIGURES 4 and 5.

FIGURE 10 is a view similar to FIGURE 6 and differs only to the extent that, instead of all the loops being out after being formed in the manner shown in either FIG- URE 1 or FIGURE 8, only a few of the loops are cut to provide tufts T while loops of intermediate height I remain intact as well as any intervening ground-engaging or low loops L which may have been formed on the base fabric. It is apparent that, in forming tufts T, the loops of which they are formed are actually raised to a higher level than intermediate loops I so that subsequent shearing of the fabric cuts only the high loops to produce the tufts T. The showing of FIGURE 10 is merely for purposes of illustrating various types of fabrics which may embody the mottled effects produced acording to the present invention. Accordingly, a detailed illustration and description of the fabric shown in FIGURE 10 is deemed unnecessary, it being deemed sufficient to state that the loops of different heights and intervening tufts may be produced by means such as that disclosed in US. Patent No. 2,860,669, granted to Ivar O. Moberg on November 18, 1958.

In the drawings and specification there have been set forth preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. The method of making pile fabrics which comprises weaving a base of groups of warps and wefts, concurrently raising and shogging a single pile yarn over alternate groups of warps and shogging a pair of pile yarns, each of a different color and differing in color from said single pile yarn, over each intervening group of warps between said alternate groups, and looping said pile yarns under certain alternately spaced wefts at one side of the respective groups of warps and under certain intervening wefts between said alternately spaced wefts at the other side of the respective groups of warps to form pile loops of varying appearance over the face of the fabric.

2. The method of making pile fabrics which comprises interweaving spaced groups of warps with wefts while raising and shogging a single pile yarn, of a given color over each alternate group of warps, raising and shogging a pair of pile yarns, each of a different color and differing in color from said single pile yarn, over each intervening group of warps, looping said single pile yarn and said pair of pile yarns under alternate wefts at one side of the respective groups of warps and under intervening wefts at the other side of the respective groups of warps, and severing the pile yarns at points above the respective groups of warps to form variegated tufts of random disposition over the face of the fabric.

3. The method of making pile fabric which comprises weaving a base from warps and wefts while spacing cer tain adjacent warps from each other and interweaving warpwise pile yarns with said warps and wefts by shogging a single pile yarn of a given color weftwise across and above alternately spaced warps defining said spaces and passing the latter pile yarn beneath alternate wefts on one side of the latter warps and beneath intervening wefts at the other side of the latter warps, shogging an even number of the pile yarns, each of a different color and differing in color from said given color, weftwise across and above each of the intervening warps defining said spaces and disposed between said alternate warps while also passing said even number of pile yarns beneath alternate wefts on one side of said intervening warps and beneath intervening wefts on the other side of said intervening warps to form a single pile loop of said given color between adjacent wefts and extending over alternate warps and to form an even number of pile loops of different colors between said adjacent wefts and extending over said intervening warps.

4. The method of claim 3 including the step of severing said loops to form a cut pile face having a tweed-like appearance.

5. The method of making pile fabric which comprises interweaving spaced groups of warps with wefts while shogging an odd number of pile yarns each of a different color over each alternate group of warps and while shogging an even number of pile yarns, each of a different color and of a different color than said odd number of pile yarns, over each intervening group of warps, and looping said odd and even pile yarns under alternate wefts at one side of the respective groups and under intervening wefts at the other side of the respective groups to form piles of different colors randomly disposed over the face of the fabric.

6. The method of making pile fabrics which comprises interweaving spaced groups of warps with wefts while shogging an odd number of pile yarns each of a different color over each alternate group of warps, shogging an even number of pile yarns, each of a different color and of a diflerent color than said odd number of pile yarns, over each intervening group of warps, looping said odd and even pile yarns under alternate wefts at one side of the respective groups of warps and under intervening wefts at the other side of the respective groups of warps, and severing pile yarns shogged over the groups of warps to form tufts.

7. The method of making carpet fabrics which comprises interweaving spaced groups of ground warps with weft yarns; concurrently raising and shogging an odd number of pile yarns each of a different color across and above certain alternate groups of warps and beneath certain spaced Weft yarns at one side of each respective alternate group of warps and beneath certain intervening weft yarns at the other side of each respective alternate group of warps; while raising and shogging an even number of pile yarns, each of a different color and of a different color than said odd number of pile yarns, across and above certain intervening groups of warps 7 and beneath said certain spaced and said certain intervening Weft yarns at opposite sides of each respective intervening group of warps to form pile loops of different colors over respective alternate and intervening groups of warps.

8. A method according to claim 7 including severing the base in the form of tufts, a of other pile yarns looped beneath intervening weft yarns between said alternate weft yarns and extending from the base in the form of tufts between each adjacent pair of groups of warp yarns, and each of the pile yarns between any adjacent groups of warp yarns being of a difierent color than the other pile yarns between the respective adjacent groups of warp yarns.

10. A pile fabric comprising a base formed of groups of warp yarns interwoven with weft yarns, one pile yarn looped beneath alternate weft yarns between each adjacent pair of groups of warp yarns and being raised above and across one of the groups of said adjacent pair, a pair of. other pile yarns looped beneath intervening weft yarns between said alternate weft yarns and being raised above and across the other group of warp yarns in said adjacent pair, and each of the'pile yarns between any ad jacent groups of warp yarns being of a different color than the other pile yarns between the respective adjacent groups of warp yarns.

1 1. A pile fabric comprising groups of warp yarns interwoven with weft yarns to form a base, adjacent weft yarns and warp yarns defining warpwise and weftwise rows of openings therebetween, an uneven number of pile strands including at least three pile strands each of a different color and forming a like number of tufts projecting outwardly from the base at each ofsaid openings,

yarns and Warp yarns defining warpwise and weftwise rows of openings therebetween, an uneven number of pile strands including at ieast three pile strands each of a different color and forming a like number of tufts projeoting outwardly from the base at each ofrsaid openings, some of the strands in each warpwise row of openings being looped beneath alternately spaced weft yarns and the remainder of the strands in each warpwise row of openings being looped beneath intervening 'weft yarns.

1 3. An improved pile fabriclincluding a base having warp yarns interwoven with weft yarns, adjacent warp yarns and weft yarns defining openings therebetween extending in both warpwise and weftwise rows, each of said openings having an odd number of tufts therein, each of a different color, formed from pile yarn, an oddnumber of said pile yarns in each warpwise row of openings being looped beneath alternately spaced weft yarns, and an even number of pile yarns in each warpwise row of openings being looped beneath certain intervening weft yarns between said spaced weft yarns.

14. A pile tabric including a base having weft yarns interwoven with strands of warp yarn, certain adjacent pairs of said strands each being spaced apart sufliciently for receiving therebetween a group including an evenv number and an odd number of warpwise extending strands of pile yarn, each of the strands of pile yarn in each pair of adjacent odd and even groups being of a color differing from thatof the other strands of .pile yarn in the respective pair of odd and even groups, saideven number pile yarn being looped beneath alternately spaced weft yarns and raised above and across one of the strands of warp yarn of said pair, and said odd number pile yarn being looped beneath intervening strands of weft yarn and raised above and across theother of the strands of warp yarn of :said pair.

References Cited in the file of this patent UNITED STATES PATENTS Re. 23,837 Waite June 8, 1954 2,497,716 Bl'ech etial Feb. 14, 1950 2,655,951 Clark Oct. 20, 1953 2,860,669 Moberg Nov. 18, 1958 2,924,251 Nowicki et a1 Feb. 9, 1960 FOREIGN PATENTS I 148,433 Australia Sept. 29, 

1. THE METHOD OF MAKING PILE FABRICS WHICH COMPRISES WEAVING A BASE OF GROUPS OF WARPS AND WEFTS, CONCURRENTLY RAISING AND SHOGGING A SINGLE PILE YARN OVER ALTERNATE GROUPS OF WARPS AND SHOGGING A PAIR OF PILE YARNS, EACH OF A DIFFERENT COLOR AND DIFFERING IN COLOR FROM SAID SINGLE PILE YARN, OVER EACH INTERVENING GROUP OF WARPS BETWEEN SAID ALTERNATE GROUPS, AND LOOPING SAID PILE YARNS UNDER CERTAIN ALTERNATELY SPACED WEFTS AT ONE SIDE OF THE RESPECTIVE GROUPS OF WARPS AND UNDER CERTAIN INTERVENING WEFTS BETWEEN SAID ALTERNATELY SPACED WEFTS AT THE OTHER SIDE OF THE RESPECTIVE GROUPS OF WARPS TO FROM PILE LOOPS OF VARYING APPEARANCE OVER THE FACE OF THE FABRIC.
 9. A CUT PILE FABRIC COMPRISING A BASE FORMED OF GROUPS OF WARP YARNS INTERWOVEN WITH WEFT YARNS, ONE PILE YARN LOOPED BENEATH ALTERNATE WEFT YARNS BETWEEN EACH ADJACENT PAIR OF GROUPS OF WARP YARNS AND EXTENDING FROM THE BASE IN THE FORM OF TUFTS, A PAIR OF OTHER PILE YARNS LOOPED BENEATH INTERVENING WEFT YARNS BETWEEN SAID ALTERNATE WEFT YARNS AND EXTENDING FROM THE BASE IN THE FORM OF TUFTS BETWEEN EACH ADJACENT PAIR OF GROUPS OF WARP YARNS, AND EACH OF THE PILE YARNS BETWEEN ANY ADJACENT GROUPS OF WARP YARNS BEING OF A DIFFERENT COLOR THAN THE OTHER PILE YARNS BETWEEN THE RESPECTIVE ADJACENT GROUPS OF WARP YARNS. 